Welded water wall boiler



June 12, 1956 OLSEN WELDED WATER WALL BOILER 5 Sheets-Sheet 1 Filed March 28, 1955 INVENTOR Gusmv 1.. 0mm.

ATTORN EY June 12, 1956 Q EN WELDED WATER WALL BOILER Filed March 28, 1955 5 Sheets-Sheet 2 INVENTOR Gusmv 01m.

ATTORNEY INVENTOR Gusmv E. 01:5. 21%

ATTORNEY June 12, 1956 OLSEN 2,749,887

WELDED WATER WALL BOILER Filed March '28, 1955 5 Sheets-Sheet 4 INVENTOR 25a Gama 50mm.

E ATTORNEY June 12, 1956 OLSEN WELDEID WATER WALL BOILER 5 Sheets-Sheet 5 Filed March 28, 1955 \R a gm \M mm km TTORNEY United States Patent WELDED WATER WALL BOILER Gustav E. Olsen, Arverne, N. Y.

Application March 28, E55, Serial No. 497,191

14 Claims. (Cl. 122-73) The present invention relates to boilers and particularly to internally-fired, self contained steel plate boilers for steam or hot water heating systems; for supplymg service hot water and for process steam, burning any fuel but more specifically oil or gaseous fuels. 'It embodies a novel arrangement and integration of sub-assembled component parts simplifying boiler construction and lowering the costs thereof, improving combustion, directing flue-gas travel, increasing boiler water circulation, obtaining higher boiler efficiency and minimizing internal water-side corrosion by short-circuiting corrosive gases and air dissolved in the boiler water.

One object of the present invention is the reduction of boiler manufacturing costs by employing sub-assembled major component parts and simplifyingtheir final assembl iknother object is the improvement of combustion by mixing and directing the flow of combustible gases.

Another object of the present invention is providing portable selective bafliing'to divert combustion flue gases after leaving the combustion chamber into predetermined parallel or series paths or into a combination thereof and the facility for readily relocating such baffling to improve combustion and boiler efliciency and to secure maximum heat transfer compatible with the fuel burned and the draft available therefor.

A further object is the preventing of water-side pitting and corrosion of boiler plate and lines 'by virtue of the separation of the flue-bank chamber water spaces from the adjoining and interconnected water spaces thereby achieving the short-circuiting and rapid venting of dissolved corrosive gases and air normally present in boiler water to the upper steam or water chamber of the :boiler While diverting gas-and air-free water into the flue-bank chamber and speeding up water circulation.

Further objects of the present invention and an explanation of the design and the methods of assembly and construction, combustion, water circulation, combustion flue gas bafliing and other advantages will be better understood as the description proceeds.

The accompanying drawings show, for purposes of illustrating the present invention, one embodiment in which the invention may take form, together with modifications of certain parts, it being understood that the drawings are illustrative of the invention rather than limiting the same.

In the accompanying drawings:

Figure 1 is an exploded perspective view illustrating a set of component parts employed in constructing .the boiler;

Figure 2 is aperspective view of the assembled boiler, parts broken away to show interior construction;

Figure 3 is a front, elevational view of the boiler with parts in section on the line .3-3 of Fig. 6; 1

Figure 4 is a vertical sectional view on the line 44 o'fFigs. '3, 5, 6, '7 and I8;

ice

Figure Sis a rear elevational 'view of the boiler with parts in section on the line 5--5 of Figs. 4 and 6;

Figure 6 is a horizontal sectional view taken on the broken line 66 of Figs. 4 and .5;

Figure 7 is a horizontal sectional view on the broken line 77 of Fig. 4;

Figure 8 is a horizontal sectional view on the broken line 8-8 of Fig. 5;

Figure 9 is a fragmentary sectional view on-the line 99 of Fig. 10 illustrating one form of bafliing to force more of the products of combustion through the fire tubes of the water tank and the space above'it;

Figure 10 is a section on the line 10-I0 of Fig. 9;

Fig. 11 is a fragmentary, vertical sectional view on a line 1111 of Figs. 12 and 13 illustrating the boiler with another form of bathing;

Figures 12 and 13 are sectional views on the lines 12-12 and 13-13 of Fig. 11; respectively;

Figure 14 is a fragmentary, vertical sectional view on a line 1414 of Figs. 15 and 16 illustrating the boiler with another form of baffling; and

Figures 15 and 16 are transverse sectional views on the lines 15-15 and 1616 respectivelyof Fig. 14.

The boiler is designed so that it can be constructed from flat plates, fire tubes or plate fabricated flues, external pipes and pipe fittings. The component parts shownin Figure -1 will first be described.

In this figure are shown two side panels S, S, a front panel F, a rear panel R, which form the side walls of the boiler and provide the fire box walls and the water leg of the boiler.

The side panels S, S are made from boiler plate by welding together an outside rectangular-shell plate "10, an inner, shorter rectangular fire box plate 11, a narrow front plate 12, a rear plate 13, a bottom plate 14 and stay bolts 14. If desired, the front and rear plates '12 and 13 and bottom plate 14 may be bent flanges integral with the plates It) or 11.

The front panel F is made from an outer front wall plate 15, an inner fire box plate 16, top flange 17 and bottom flange 18. Flanges 1'7 and 18 may be separate pieces. Between the plates 15 and 16 are preferably deflector plates 16a, 16b. The top plate 17 extends forwardly of the front plate 15, as indicated at 17' to form the lower wall of a clean-out door opening. The rear panel -R is constructed from plates 19 and 20 and flanges 21 and 22 in a manner similar to the front panel, the top flange 21 extending rearwardly as indicated at 21'. The panel =R also has stay bolts as indicated at 22'.

In assembling the boiler shown in the drawings, the front and rear panels are placed between the side panels and in order to permit water circulation throughout the panels, the inner side walls 11, 11 of the side panels are provided with upper rear holes 23, lower rear holes 2'4, or slotted cut-outs, opposite the :open ends of rear panel R, and upper and lower holes 25, 25a or siotted cutouts opposite the'open ends 'of the .front panel F. If the proportions of the boiler were such that it was desirable to have the side panels received between the front and rear panels, the front and rear panel's would have closed sides similar to the closed sides of the side panels shown, and the side .panels would have open sides similar to the open sides of the front and rear panels shown.

.A top plate 26, has a length and width corresponding with the length and width of the outer walls of the side, front and end panels (5 S F R). A fire box cover sheet or crown sheet '27 is of 'a width to extend between the inner walls 11, 11 of the sid'epanels 5,8, and is 'lon'ger'than the width of these panels as indicated by the front and rear margins 27a and 27b. The side plates 10, 10 'are connected by stay bolts 2'8. The top plate 26 and cover sheet 27, are connected by stay bolts 29, 29. A rear plate is placed in the rear between the plates 26 and 27 and the outer plates 10, 10. A front plate 31, is similarly placed at the front. This plate has a hole 32 adapted to receive a domestic hot water coil indicated at 33, Figure 4. If desired, the hot water coil may be inserted through a hole in the rear plate 30.

Narrow side plates 34 and 35 extending between the front extensions 27a and 17 form, together with these extensions, a front cleanout door opening 36, adapted to be closed by a door 37. Opposite the door opening 36, is a horizontal flue bank chamber or water tank T in the form of a rectangular box having front and rear end walls 38 and 39 connected by fire tubes or flues 40, also side walls 41, 41, top wall 42, and bottom wall 43. The top wall 42 is below the fire box cover sheet 27. The tank space is connected to the space above the cover sheet 27 by water tubes 44, 44 and at the lower front thereof with the front panel F by a sloping water tube or riser 45.

The rear end of the tank rests on the flange 21 of the rear panel R and extends beyond into the smoke box 50. It is connected in the rear to the bottom of the rear portion R of the water leg by a return or downward recirculating pipe indicated at 46 (Fig. 4). This pipe may be connected to a drainage valve 47. The smoke box 50 is shown rectangular. It fits the rear of the boiler body above the cover sheet 27 and underneath flange 21 and has either top or rear connections 50a, 50b for a smoke pipe.

The components above referred to except for the door, are welded together to form the boiler body shown in detail in Figures 2 to 8 inclusive. The boiler has a rectangular fire box adapted to receive a suitable lining and burner or grates or stoker as desired. Below the front water leg panel, the body has a removable closure plate 48.

When used for steam, the boiler will have the usual pressure gauge 51 safety valve 52 and gauge glass 53. The boiler is connected to a feed water and condensation return line as indicated at 54, preferably above the level of recirculation line 46. The steam or hot water for heating is delivered to the outlet connection 55 in the top plate 26. The water legs are provided with bottom clean-outs 56, and 57 to facilitate cleaning, flushing and draining.

Water fills the front and rear panels, the side panels and part or all of the space above the cover sheet 27. The circulation path of the water in the boiler is indicated by arrows w with light solid lines. The hot water return or condensate and raw make-up water enters inlet 54 at the lower rear part of the boiler, the farthest from riser pipe 45, which connects the front panel F and tank T. By having this return feed pipe above the re-circulating connection 64, upward venting of corrosive gases through the latter is prevented. The return water as well as the recirculated water from pipe 46 passes from the rear panel R through the upper holes 23 and lower holes 24 into the side panels. In these side panels part of the water passes up into the chamber above the fire box cover plate 27 and part passes through lower holes 25 into the front panel, where part of this water with air or gas bubbles, if any, is deflected laterally by the plates 16a toward the holes 25a and air-free water rises through the pipe 45 into the tank T. Water and steam heated in the tank rise through tubes 44. Thermo-syphon action of the riser 45, tank T and return pipe 46, make it possible to maintain a circulation of water independent of that which involves condensate return or circulation through the radiators. This facilitates heating the water, particularly when the boiler is operated for domestic hot water heating only.

During the travel of the water in the boiler, increasing temperatures accelerate circulation and liberate dissolved corrosive gases and air which rise in the side water legswithout entering the riser 45, so that the tank is substan tially free of such gases and air. Steam and gas bubbles formed in the water rise in paths indicated by arrows b with wavy lines short-circuiting flue bank T.

The basic boiler shown in Figures 1 to 8 inclusive is an embodiment designed more particularly for incidental recovery of heat, as hot water or steam, under conditions where fuel cost is unimportant, as when burning refuse or waste. Here the products of combustion pass through the side or peripheral spaces 58, 58 between the tank T and the plates 11, 11, through fire tubes 40 and through the upper peripheral space 59 between the tank and fire box cover sheet 27 wth a minimum of resistance or draft loss. The stack temperature is high and a high combustion rate may then be secured. The paths of products of combustion for this arrangement are indicated by the dotted arrows g.

The boiler shown in Figures 9 and 10 is an adaptation of the boiler of Figures 1-8 designed for use with costly fuel. It forces the products of combustion along a circuitous path with a large quantity going through the tubes or fines in the tank. The same reference characters are employed for corresponding parts. This boiler may employ all the parts above described, and in addition has a front baffle 60 above the riser 45 to prevent gases from passing from the fire box directly to the front ends of fire tubes 40, top baflles 61 and 62 to prevent the gases from rising above the sides of the tank and rear bafiies 63 and 64 to prevent the gases from passing directly from the fire box to the smoke box. This baifling compels the gases to rise through the side spaces 58 pass forwardly of the tank into the chamber formed above the plate 60 before they pass rearwardly through the top space 59 and through the fire tubes. This construction effects two passes of the gases as shown by the dotted arrows g in these figures with increased heat transfer.

The boiler shown in Figures 11, 12 and 13 has the same basic structure as that shown in Figures 1 to 8 inclusive but another form of baflling. Here, the front plate 70, similar to the plate 60 of Figures 9 and 10 has extensions 71 and 72, which extend part way up across the side spaces 58, and top and rear side baffles 73, 74 and 75 which close off the rear of the side and top passages 58 and 59 so that the gases must pass up through the side spaces and top space 59, and pass forwardly of the tank T before they all can enter the tubes 40. This construction effects three passes as indicated by the dotted arrow g" in these figures, with further increased heat transfer and efficiency.

The boiler shown in Figures 14 to 16 again has the same basic structure as shown in Figures 1 to 8 but another form of baffiing. Here, direct passage of gases to the chimney is prevented by rear baffles 76 and 77 closing off the rear of side passages 58, and the rise of gases through these passages is interrupted by a horizontal baflle 79 above the level of the lower tier of the fire tubes. This baffle has sides 79a, 79b in the spaces 58 and a front end 79c which extends to the clean-out door. It compels all the gases to pass rearwardly through the lower fire tubes. Additional baflles 80 and 81 extend upwardly from baflles 76 and 77 and the ends 79a, 79b of baffle 79 to meet a rearwardly extending baffle 82 which closes off the lower part of the smoke box and compels the gases to pass forwardly through the upper tubes of the tank T. The gases finally escape through the upper part of space 58 and through space 59. This construction effects four passes as indicated by the dottedarrows g in these figures.

Baffles are made of scrap boiler plate or other suitable material of heat resisting character readily adjustable in the field to suit local conditions for best operating results. Easy access to combustion spaces and to bafiling can be had through the front and rear openings opposite the tank T. Baffles are held in position by their own weight or they may be wedged in place, bolted or tack welded. Boilers would normally be shipped with baffles in the best position for the fuel and draft to be encountered with provision for field changing if required. The de scribed and illustrated bafliing or other suitable arrangements thereof, it should now be apparent, permit the boiler user to regulate the combustion flue-gas paths to suit local conditions to obtain maximum boiler efliciency in contrast to other boilers with fixed combustion fluegas travel, the latter with no regard for draft available or fuel to be burned, which fuel conceivably could change after installation between oil, gas and coal depending on fuel cost and local availability.

Combustion in the combustion chamber is improved by the baffling referred to owing to the induced forward travel ,of the combustible gases giving more thorough intermingling of combustible gases and air than otherwise possible were the gases uncontrolled and permitted before and after burning to exit into the chimney by the shortest path that they would normally follow.

With .further reference to dissolved corrosive gases and air in the boiler water, in conventional boilers such gases along with the feed water and returning condensation, are normally permitted to flow uncontrolled through the tube bank resulting in gas and air bubbles adhering to the tube and plate surfaces causing eventual pitting and corrosion, which conditions are avoided in my invention by short-circuiting corrosive gases and air as herein explained.

Heat transfer is also enhanced owing to the added large areas of horizontal heat absorbing surfaces 42 and 43 of tank T located in the upper portion of the combustion chamber or fire box of the boiler and the fire box cover sheet 27, giving the equivalent of three highly elfective horizontal crown-sheets swept by combustion gases and by waterside circulation in contrast to the one horizontal crown sheet of conventional boilers.

By making front to rear-components of two sizes and side to side components of about four sizes, a wide range of boiler capacities may be obtained from different assemblies of these components.

The arrangement of components shown in Fig. 1 is illustrative of an arrangement suitable for prefabrication and subassembly with simple, inexpensive machinery and equipment and in a form suitable for storage and later assembly.

Where storage is not a problem, and more expensive machinery and equipment is available, more complicated components may be made, for example, the top maybe integral with one .or both of the outer side walls, the fire box cover sheet may be .integral with one or both of the inner side walls, or the ends of the closed legs may be bent out of the same sheet of metal which forms an inner or outer side wall.

Since it is obvious that the invention may be embodied in other forms and constructions within the scope of the claims, I wish it to be understood that the particular forms shown are but a few of these forms and, various modifications and changes being possible, I do not otherwise limit myself in any way with respect thereto.

What is claimed is:

1. A boiler having a rectangular water leg which forms a rectangular fire box and having upwardly opening side portions which are higher than the front and rear portions, the latter portions being closed at their respective tops and bottoms, a fire box cover sheet connecting the side portions and above the front and rear portions to form front and rear openings; front, rear and top plates forming a water chamber above the cover sheet and in communication with the open water leg sides, a horizontal water tank spaced below the cover sheet to form an upper flue gas passage and spaced from the inner side walls of the side portions of the water leg to provide lateral flue gas passages, the tank extending through the rear opening and having horizontal fire tubes, means forming a water circulation passageway connecting the lower front portion of the tank with an adjacent portion of the water leg to permit flow of water into the tank, a return tube 6 connecting the rear .of the tank with the rear portion of the water leg, and means forming a water circulation passageway from the upper portion of the tank to the water-containing space to facilitate flow of heated water from the tank.

2. The boiler of claim 1, wherein each side portion of the water leg includes a relatively long outer plate, a relatively short inner plate spaced from the outer plate, and end and bottom members, the inner plate having openings disposed opposite the ends of the front and rear water leg portions 3. The boiler of claim 1, wherein the front and rear portions of the water leg each have inner and outer walls and top and bottom walls, and are open at the ends thereof.

4. The boiler of claim 1, wherein the cover sheet and front water leg portions have forward extensions and the cover sheet and rear water leg portions have rearward extensions.

5. The boiler of claim 1, having upper and rear battles in the lateral flue gas passages which prevent the passage of flue gases directly from the fire box through the rear opening, and a front baflle which prevents flue gases from passing directly from the fire box to the front of the fire tubes, whereby the gases are forced forwardly along the sides of the tank before they can enter the fire tubes or the upper flue gas passage.

6. The boiler of claim 1, having near the rear of the tank side baffles which prevent the passage of flue gases directly from the fire box through the rear opening, a rear baffle which prevents passage of gases rearwardly through the top gas passage, and a front baflle and extending partway across the side gas passages whereby all the flue gases are directed into paths which require passage through the fire tubes in a rearward direction.

7. The boiler of claim 1, wherein the tank has an upper and a lower bank of fire tubes, and having a horizontal bafiie intermediate the level of the upper and lower banks of tubes and extending across the space in front of the tank and through the lateral flue gas spaces, and a bafile in the rear of each of the lateral gas passages whereby the flue gases are forced to enter the lower bank of tubes at the front end thereof, and a chamber enclosing the rear end of the tank for redirecting the gases forwardly through the upper bank of tubes before they pass rearwardly through the upper gas passage.

8. A rectangular boiler having a fire box forming .a water leg including two side portions and a rear portion extending to the bottom of the boiler and a front portion terminating above the bottom of the boiler to provide a. firing opening, there being water passages which enable water to circulate throughout the water leg, the front and rear portions of the water leg being closed at the top thereof, theside portions of the water leg each having an outer wall and an inner wall which terminates below the top of the outer wall and above the top of the front and rear portions, a fire box cover sheet connecting the inner side walls of the side portions and terminating above the tops of the front and rear portions to provide front and rear openings, front and rear closure plates between the side walls and above the cover sheet, a top wall connecting the front and rear closure plates and the top of the side walls to form an upper water and/or steam chamber, a horizontal water tank spaced below the cover sheet to provide :an upper flue gas passage and from the inner side walls of the rear portions of the water leg to provide lateral flue gas passages, the water tank extending through the rear opening and having horizontal fire tubes, means forming a water circulation passageway connecting the lower front portion of the tank with an adjacent portion of the water leg to permit flow of water into the tank, a return tube connecting the tank and the rear water leg, means forming a water circulation passageway from the upper portion of the tank to the water-containing space to 7 facilitate flow of heated water from the tank, and a closure for the front opening.

9. A rectangular boiler having a fire box having two opposite inner vertical side walls, a cover sheet at the top of said side fire-box-forming walls, the fire box also having front and rear inner side walls terminating below the level of the cover sheet to form a rectangular fire box and a front clean-out door opening and a rear smoke passage, outer side walls extending above and spaced from the inner fire box side walls to provide water and/ or steam passageways, front and rear outer walls spaced from the front and rear fire box walls and secured thereto at the top to form a closure and prevent upward passage of 8 tops to prevent passage of water and/ or steam upwardly into the space above the fire box cover sheet and to also form the lower edges of the door opening and smoke passage respectively, water circulation passages connecting the front, side and rear water spaces, a horizontal tank in the upper part of the fire box and extending through the smoke passage, the tank having horizontal fire tubes opening opposite the clean-out door and rearwardly, a

' fire box contained riser tube connecting the front water steam and/or water, a top plate across the top of the outer side walls, front and rear end plates between the top plate and fire box cover sheet, a water tank mounted in the fire box opposite the clean-out door opening below the fire box cover sheet, the tank being of less width and height than the smoke passage and extending rearwardly through the same, the tank having longitudinally extending fire tubes, means forming a water circulation passageway connecting the lower front portion of the tank with an adjacent portion of the water leg to permit fiow of water into the tank, riser connections between the tank and the space above the fire box cover sheet, and a return connection from the tank outside the fire box and opening into the water space below the smoke passage.

10. A rectangular boiler having double walled front and rear panels closed at the bottom and top; double walled side panels taller than the front and rear panels and open at the top at an elevation above the top of the front and rear panels; means securing the four panels together to form a rectangular fire box and provide passageways interconnecting the panels for circulation of water; a fire box cover sheet secured across the top of the inner walls of the side panels; a top plate secured across the top of the outer walls of the side panels; front and rear wall-forming-means above the front and rear panels; a heat interchanger mounted in the fire box below the fire box cover sheet and extending through the rear wall forming means, the interchanger having a water tank traversed by horizontal tubes which at the front open into the fire box and at the rear open beyond the rear wall forming means; outlet passages from the top of the tank through the fire box cover sheet; means forming a water circulation passageway connecting the lower front portion of the tank with an adjacent portion of the water leg to permit fiow of water into the tank; an externally disposed return tube connecting the bottom of the tank and the water leg; and means forming a water circulation passageway from the upper portion of the tank to the water-containing space to facilitate flow of heated water from the tank.

11. A boiler having outer side walls, a front wall provided with a clean-out door opening and door, a rear wall provided with a smoke passage, a top plate across the top of the side, front and rear walls, inner side Walls opposite to and spaced from the outer side walls and extending up to the upper portion of the smoke passage, a fire box cover sheet connecting the top edges of said inner side walls so that water and/ or steam may pass upwardly into the space above the fire box cover sheet, inner front and rear walls opposite to and spaced from the outer front and rear walls and connected to the corresponding outer walls to form front and rear water spaces closed at their space and the tank, other passages connecting the tank and the space above the fire box cover sheet, and a return circulation tube outside the fire box and connecting the tank and the lower portion of the water circulation space.

12. A boiler with a rectangular fire box and water leg formed of two double walled side panels and double walled front and rear panels, all of which are closed at the bottom, two opposite panels being closed at the sides thereof, two opposite panels being open at the sides thereof and assembled with the first two panels to form a four-' sided fire box, the portions of the inner walls of the first; two panels opposite the open sides of the other two panels having holes to permit water circulation about the interior of the four panels, one opposite pair of panels being closed at the top, the other opposite pair being open at the top and each having an outer side wall above the upper edge of the inner side wall.

13. The boiler of claim 12 having a fire box cover sheet across the upper edges of the inside walls of the side panels, a top head plate across the upper edge of the outside wall of the side panels, and front and rear walls above the front and rear panels.

14. A boiler having an upper water chamber, front, rear and side Water legs in communication with the chamber and forming a fire box closed at the top, the rear Water leg terminating a substantial distance below the top of the fire box to provide an opening, a water tank in the upper part of the firebox, the tank having horizontal fire tubes and extending rearwardly through the opening above the rear water leg, the sides of the tank being spaced from the inside walls of the side water legs, the top of the tank being spaced below the top of the fire box so that products of combustion may pass through the side and top spaces and the tubes, means forming a water circulation passageway connecting the lower front portion of the tank with an adjacent portion of the water leg to permit flow of water into the tank, a return pipe connecting the tank to the lower portion of the rear water leg, and means forming a water circulation passageway from the upper portion of the tank to the water-containing space to facilitate flow of heated water from the tank.

References Cited in the file of this patent UNITED STATES PATENTS 13,111 Thomas June 19, 1855 1,605,554 Miller Nov. 2, 1926 1,832,311 Lockett et al Nov. 17, 1931 1,982,793 Davis Dec. 4, 1934 2,095,527 Menk Oct. 12, 1937 2,200,809 Riehl May 14, 1940 2,270,048 Gray Jan. 13, 1942 FOREIGN PATENTS 650,559 Great Britain Feb. 28, 1951 

